Manufactured reinforced concrete system

ABSTRACT

A self-reinforcing in-situ concrete form that receives concrete including a first panel having a first surface and a second surface positioned opposite to the first surface, and a reinforcement rib connected to the first surface of the first panel, the reinforcement rib generally including a retention surface spaced away from the first surface of the first panel, wherein the retention surface is positioned in a non-perpendicular alignment with the first surface of the first panel, and the panel and the retention surface are designed to stay attached to the concrete after the concrete cures.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 60/278,062, filed Mar. 22, 2001, entitled “Manufactured Reinforced Concrete System,” which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to static structures and, more particularly, to in-situ concrete forms and concrete reinforcing.

[0004] 2. Brief Description of the Prior Art

[0005] In-situ concrete forms are generally known to one skilled in the art. For example, U.S. Pat. No. 5,860,262 to Johnson generally discusses that Thomas Edison invented a method for casting a monolithic concrete structure in situ. The Johnson patent further describes the Edison method as “cumbersome” and “unwieldy” due to the weight of the in situ concrete forms. U.S. Pat. No. 6,070,380 to Meilleur indirectly addresses the problems associated with the earlier Edison design and generally discloses a two-panel prefabricated concrete framework.

[0006] Despite the improvements in vertical concrete barrier construction over the past century, there still exists a need for a generally lightweight, pre-fabricated, in situ vertical concrete form which has at least one panel and one which functions both as a concrete form and concrete reinforcement. A need also remains for concrete forms which removes the need for pre-casting and allow all concrete to be poured at the construction site.

[0007] This application is being concurrently filed under the Patent Cooperation Treaty, so the following patents are being listed for PCT purposes in lieu of the Information Disclosure Statement required under United States patent practice. The following patents are not admitted prior art, and are only included to assist the PCT Examiner with his or her search: U.S. Pat. No. 5,809,726 to Spude; No. 5,729,945 to Menchetti et al.; No. 5,553,430 to Majnaric et al.; No. 4,018,021 to Dow; and No. 520,137 to Deslauriers.

SUMMARY OF THE INVENTION

[0008] To help further the art of in situ vertical concrete forms, the present invention generally includes at least one panel and at least one a reinforcement rib connected thereto which bears a retention surface nonperpendicular with the panel. This configuration combines formwork with conventional reinforcing into a single unit. This simplifies field erection and saves labor time and reinforcing material.

[0009] One embodiment of the present invention includes an in-situ concrete form that receives concrete including a first panel having a first surface and a second surface positioned opposite to the first surface, and a reinforcement rib connected to the first surface of the first panel, the reinforcement rib comprising a retention surface spaced away from the first surface of the first panel, wherein the retention surface is positioned in a nonperpendicular alignment with the first surface of the first panel, and the panel and the retention surface are designed to stay attached to the concrete after the concrete cures.

[0010] The first panel may be made from a material selected from the group consisting of aluminum, steel, hot-rolled steel, cold-rolled steel, stainless steel, embossed steel, pickled and oiled steel, or steel having a rust inhibitor coating. The reinforcement rib defines a shape selected from the group consisting of a C-shape cross-section, a Z-shape cross-section, and a triangular-shape cross-section, wherein the C-shape cross-section and the Z-shape cross-section each generally include a base arm, an extension arm connected to the base arm, and a retention arm connected to the extension arm, wherein the retention arm defines the retention surface. The triangular-shape cross-section reinforcement rib generally includes three spaced apart rods and an internal support lattice. The reinforcement ribs are preferably made from a material selected from the group consisting of steel, hot-rolled steel, cold-rolled steel, stainless steel, embossed steel, pickled and oiled steel, and coated steel.

[0011] A second panel may be positioned opposite to the first panel. The second panel generally includes a first surface, a second surface positioned opposite to the first surface, and a reinforcement rib connected to the first surface of the second panel. The reinforcement rib generally includes a second retention surface spaced away from the first surface of the second panel, wherein the second retention surface is positioned in a nonperpendicular alignment with the first surface of the panel. A removable spacer bar may be positioned between the second surface of the first panel and the second surface of the second panel and the removable spacer bar may be slideably movable and further include attachment means slideably connected to the removable spacer bar.

[0012] A method of creating a concrete wall may include the steps of a) installing a first panel having a first surface, a second surface positioned opposite to the first surface, and a reinforcement rib connected to the first surface of the first panel, the reinforcement rib generally including a retention surface spaced away from the first surface of the first panel, wherein the retention surface is positioned in a non-perpendicular alignment with the first surface of the first panel, b) pouring concrete adjacent to the first surface of the first panel such that the reinforcement rib extends into the concrete, and c) curing the concrete. Additional steps may include d) applying a decorative or rust-inhibition coating to the second surface of the panel, e) installing a second panel opposite to the first panel, the second panel also having a first surface, a second surface positioned opposite to the first surface, and a reinforcement rib connected to the first surface of the panel, the reinforcement rib generally including a second retention surface spaced away from the first surface of the second panel, wherein the second retention surface is positioned in a non-perpendicular alignment with the first surface of the second panel, f) installing a removable spacer bar between the second surface of the first panel and the second surface of the second panel, g) installing an attachment means on the removable spacer bar, and h) removing the removable spacer bar after the concrete has cured.

[0013] These and other advantages of the present invention will be clarified in the description of the preferred embodiment taken together with the attached drawings in which like reference numerals represent like elements throughout.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014]FIG. 1 is a perspective side view of a panel and a plurality of first embodiment C-shaped reinforcement ribs attached thereto;

[0015]FIG. 2A is an end view of the first embodiment C-shaped reinforcement rib shown in FIG. 1;

[0016]FIG. 2B is a side view of the first embodiment C-shaped reinforcement rib shown in FIG. 2A;

[0017]FIG. 3 is a perspective side view of a panel and a plurality of second embodiment C-shaped reinforcement ribs attached thereto;

[0018]FIG. 4A is an end view of the second embodiment C-shaped reinforcement rib shown in FIG. 3;

[0019]FIG. 4B is a side view of the second embodiment C-shaped reinforcement rib shown in FIG. 4A;

[0020]FIG. 5 is a perspective side view of a panel and a plurality of Z-shaped reinforcement ribs attached thereto;

[0021]FIG. 6 is an end view of the Z-shaped reinforcement rib shown in FIG. 5;

[0022]FIG. 7 is a perspective side view of a panel and a plurality of triangular-shaped reinforcement ribs attached thereto;

[0023]FIG. 8A is an end view of the triangular-shaped reinforcement rib shown in FIG. 7;

[0024]FIG. 8B is a top view of the triangular-shaped reinforcement rib shown in FIG. 8A;

[0025]FIG. 9 is cross-sectional side view of one application of the panel and the Z-shaped reinforcement rib shown in FIG. 5;

[0026]FIG. 10 is a cross-sectional side view of a second application of the panels and the Z-shaped reinforcement ribs shown in FIG. 5; and

[0027]FIG. 11 is a top view of the panels shown in FIG. 10, with C-shaped reinforcement ribs instead of Z-shaped ribs, a slideable spacer bar, and no concrete.

DETAILED DESCRIPTION OF THE INVENTION

[0028] The present invention described herein is also described in U.S. Provisional Patent Application Serial No. 60/278,062, entitled “Manufactured Reinforced Concrete System,” herein incorporated by reference in its entirety.

[0029] The present invention generally relates to in situ concrete forms. An in situ concrete form is defined herein as a structure having one or more panels and at least one reinforcement rib connected to one side of each panel. The in situ concrete form is not removed once concrete cures adjacent to the panels and reinforcement ribs. The reinforcement rib or ribs extend into the concrete, and the panels and reinforcement ribs add structural support to the poured concrete. The reinforcement ribs attached to the panel skin substitutes for traditional reinforcement commonly known as deformed bars.

[0030] As shown in FIG. 1, an in situ concrete form 10 may include a panel 12 and a reinforcement rib 14 attached thereto. Each panel 12 generally defines a first surface 16 and a second surface 18 positioned opposite to the first surface 16. Each panel 12 is preferably made from eleven-gauge hot-rolled steel, cold-rolled steel, stainless steel, embossed steel, pickled and oiled steel, or other suitable structural material. As noted earlier, one or more panels 12 may be connected together, such as by welding or other suitable attachment method, to create differently-shaped in situ concrete forms 10. The gauge thickness of each panel 12 may be increased or decreased depending on the particular application. Moreover, the second surface 18 of each panel 12 may be embossed or conditioned to receive a decorative rust preventive, such as paint.

[0031] With continuing reference to FIG. 1, each panel 12 is preferably reinforced with a reinforcement rib 14 which may horizontally span the first surface 16 of the panel 12 at a uniform or non-uniform distance D. In one preferred spacing configuration, each reinforcement rib 14 is spaced eight to sixteen inches apart, with a spacing of twelve to sixteen inches for an eleven- or twelve-gauge steel panel 12. Each reinforcement rib 14 is preferably made from eleven-gauge steel or other suitable structural material, but other gauge thicknesses are also contemplated. The width W of each reinforcement rib 14 is approximately three to twenty-four inches, depending on the particular application, with a minimum of three inches being preferred. Standard angle iron I may be added to provide reinforcement and carrying handles for the panel 12 or panels 12.

[0032] As shown generally in FIGS. 1, 2A, and 2B, each reinforcement rib 14 may form a general C-shape in cross-section, and include a base arm 20, an extension arm 22, which preferably extends approximately three or more inches W away from the base arm 20 and the first surface 16 of the panel 12, and a retention arm 24, which defines a retention surface 26. However, a variety of additional cross-sectional shapes are also contemplated. For example, FIGS. 3, 4A, and 4B show another generally C-shaped reinforcement rib 14A which is similar to the C-shaped reinforcement rib 14 shown in FIGS. 1, 2A, and 2B, except the reinforcement rib 14A further includes one or more tabs 28 positioned adjacent to the base arm 20 and the retention arm 24. One or more of other generally C-shaped reinforcement ribs 14A may also be positioned on the first surface 16 of the panel 12 via the extension arm 22 to provide carrying handles.

[0033] Referring briefly to FIGS. 2B and 4B, each reinforcement rib 14, 14A may also define one or more passageways 34. The passageways 34 increase bond strength of the reinforcement rib 14, 14A with concrete, allow for the insertion of additional horizontally extending reinforcement ribs to increase structural value and aid in the alignment of stacked panel 12 sections, and allow for the threading of conduit piping or other embodiments.

[0034]FIGS. 5 and 6 each show a generally Z-shaped reinforcement rib 14B having a retention surface 26 defined by the retention arm 24, as well as a possible second retention surface 26A, defined by the extension arm 22. Passageways may also be defined by the Z-shaped reinforcement rib 14B. FIGS. 7, 8A, and 8B each generally show a triangular, cross-sectional-shaped reinforcement rib 14C having three spaced apart rods 30A, 30B, 30C, an open internal support lattice 32, and one or two retention surfaces 26B, 26C, depending on whether one of the rods 30A or two of the rods 30B, 30C are positioned adjacent to the first surface 16 of the panel 12. In addition to these cross-sectional shapes, other cross-sectional shapes such as a W-shape, a T-shape, an H-shape, an L-shape, or any other suitable cross-sectional shape could also be used. The only requirement is that each reinforcement rib 14 have a retention surface 26 spaced away from the first surface 16 or second surface 18 of the panel 12, preferably at a distance of approximately three or more inches, wherein the retention surface 26 is positioned in a parallel or other non-perpendicular alignment with the first surface 16 (or second surface 18) of the panel 12. For example, in the C-shaped reinforcement rib 14 shown in FIGS. 1, 2A, and 2B, the retention surface 26 is substantially perpendicular to the first surface 16 of the panel 12. In the triangular-shaped reinforcement rib 14C shown in FIG. 7, an outer surface 36 of the extended rod 30A or rods 30B, 30C define the retention surfaces 26B, 26C.

[0035] As shown generally in FIG. 9, one application of the present invention may be to help define a pit 38. In this application, a cavity 40 is excavated from the ground 42, and a plurality of panels 12 with corresponding reinforcement ribs 14B are positioned in the cavity 40. The reinforcement ribs 14B shown in FIG. 9 are the Z-shaped reinforcement ribs shown in FIGS. 5 and 6, but any other suitable cross-sectional shape may be used. The reinforcement ribs 14B are purposely spaced away from the first surface 16 of each panel 12 in FIG. 9 to clearly show the complete structure of each Z-shaped reinforcement rib 14B. However, in practice, the base arm 20 of each Z-shaped reinforcement rib 14B is connected to the first surface 16 of each panel.

[0036] Reinforcement bars 44, such as five-eighths inch diameter rebar, may be also positioned in the pit 38, particularly if a load will be carried on a base portion 46 of the pit 38. Base plates 48 may also be positioned at a second end 50 of each panel 12 to help distribute weight. Depending on the particular application, a standard footer may also be prepared adjacent to the base portion 46 of the pit 38. A temporary removable spacer bar 52 may also be added during concrete pouring to assist support until the concrete cures. In practice, the form can be suspended from above and concrete placing can be continuous from the base or floor up through the wall.

[0037] With continuing reference to FIG. 9, concrete 54 is next poured into channels 56 defined between one or more panels 12 and walls 58 of the pit 38. Other reinforcement bars 44 may also be added, depending on the amount of weight which will be carried on a working surface 60 positioned adjacent to the pit 38. The reinforcement ribs 14B extend into the concrete 54, and help to hold each panel 12 in place. Once the concrete 54 has cured, the spacer bar 52 may be removed, and the panels 12 and reinforcement ribs 14 provide structural support to the cured concrete.

[0038] Another converse application is shown in FIG. 10. As shown in FIG. 10, the present invention may be used to make a pedestal 62 for supporting a piece of machinery. In this application, panels 12 are arranged to form an open container 64 which receives concrete 54. Not the absence of rebar in the drawings because the present inventive system satisfies most civil engineering for conventional rebar; note also that rebar 44 appears in the structural floor on which the plinth is positioned. However, unlike the previous pit 38 application, the spacer bar 52 remains in place, and in this case, spacer bar 52 also acts as a positioning bar for embedded anchor bolt assemblies, as described below, or other embedded items. The spacer bar 52 adds tensile strength to an engagement surface 66 of the pedestal. Second, as shown in FIGS. 10 and 11, attachment means 68, such as threaded anchor bolts 70 housed in an oversized housing 72, may be attached to the spacer bar 52. The oversized housing 72 allows a corresponding threaded anchor bolt 70 to be aligned with a piece of machinery after the concrete 54 has cured around the oversized housing 72. Otherwise, any miscalculation in initial placing the threaded anchor bolts 70 would result in improper alignment of the threaded anchor bolts 70 with respect to the machine or other installed device. To further help with alignment, the spacer bar 52 may ride in C-shaped reinforcement ribs 14, 14A to allow movement in the A1, A2 direction and the attachment means 68 may move in the A3, A4 directions along a longitudinal length of the spacer bar 52.

[0039] As described above, the present invention is a preformed, in-situ, vertical concrete mold which is usually built in shop conditions and shipped to a site already completed or in panelized pieces that are easy to assemble on site. Each panel may have an exposed decorative surface and at least one associated reinforcement rib which is embedded in the concrete.

[0040] The invention has been described with reference to the preferred embodiment. Obvious modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. 

I claim:
 1. An in-situ concrete form that receives concrete comprising: a first panel having a first surface and a second surface positioned opposite to the first surface; and a reinforcement rib connected to the first surface of the first panel, the reinforcement rib comprising a retention surface spaced away from the first surface of the first panel, wherein the retention surface is positioned in a non-perpendicular alignment with the first surface of the first panel, and the panel and the retention surface are designed to stay attached to the concrete after the concrete cures.
 2. The in-situ form as claimed in claim 1, wherein the first panel is made from a material selected from the group consisting of aluminum, steel, hot-rolled steel, cold-rolled steel, stainless steel, embossed steel, pickled and oiled steel, and steel having a rust inhibitor coating.
 3. The in-situ form as claimed in claim 1 wherein the reinforcement rib defines a shape selected from the group consisting of a C-shape cross-section, a Z-shape cross-section, and a triangular-shape cross-section.
 4. The in-situ form as claimed in claim 3, wherein the C-shape cross-section and the Z-shape cross-section each comprise a base arm, an extension arm connected to the base arm, and a retention arm connected to the extension arm, wherein the retention arm defines the retention surface.
 5. The in-situ form as claimed in claim 3, wherein the triangular-shape cross-section reinforcement rib comprises three spaced apart rods and an internal support lattice.
 6. The in place concrete form as claimed in claim 1, wherein the reinforcement rib is made from a material selected from the group consisting of steel, hot-rolled steel, cold-rolled steel, stainless steel, embossed steel, pickled and oiled steel, and coated steel.
 7. The in place concrete form as claimed in claim 1, further comprising: a second panel positioned opposite to the first panel, the second panel also comprising a first surface, a second surface positioned opposite to the first surface, and a reinforcement rib connected to the first surface of the second panel, the reinforcement rib comprising a second retention surface spaced away from the first surface of the second panel, wherein the second retention surface is positioned in a non-perpendicular alignment with the first surface of the panel; and a removable spacer bar positioned between the second surface of the first panel and the second surface of the second panel.
 8. The in-situ form as claimed in claim 7, wherein the removable spacer bar is slideably movable and further comprising attachment means slideably connected to the removable spacer bar.
 9. A method of creating a concrete wall comprising the steps of: a) installing a first panel having a first surface, a second surface positioned opposite to the first surface, and a reinforcement rib connected to the first surface of the first panel, the reinforcement rib comprising a retention surface spaced away from the first surface of the first panel, wherein the retention surface is positioned in a nonperpendicular alignment with the first surface of the first panel; b) pouring concrete adjacent to the first surface of the first panel such that the reinforcement rib extends into the concrete; and c) curing the concrete.
 10. The method as claimed in claim 9, further comprising the step of: d) applying a decorative or rust-inhibition coating to the second surface of the panel.
 11. The method as claimed in claim 9, further comprising the steps of: e) installing a second panel opposite to the first panel, the second panel also having a first surface, a second surface positioned opposite to the first surface, and a reinforcement rib connected to the first surface of the panel, the reinforcement rib comprising a second retention surface spaced away from the first surface of the second panel, wherein the second retention surface is positioned in a non-perpendicular alignment with the first surface of the second panel; and f) installing a removable spacer bar between the second surface of the first panel and the second surface of the second panel.
 12. The method as claimed in claim 11, further comprising the step of: g) installing an attachment means on the removable spacer bar.
 13. The method as claimed in claim 11, further comprising the step of: h) removing the removable spacer bar after the concrete has cured.
 14. An in situ concrete form comprising: a first panel having a first surface and a second surface positioned opposite to the first surface; a reinforcement rib connected to the first surface of the first panel, the reinforcement rib comprising a retention surface spaced away from the first surface of the first panel, wherein the retention surface is positioned in a non-perpendicular alignment with the first surface of the first panel; and a second panel positioned opposite to the first panel, the second panel also comprising a first surface, a second surface positioned opposite to the first surface, and a reinforcement rib connected to the first surface of the second panel, the reinforcement rib defining a second retention surface spaced away from the first surface of the second panel, wherein the second retention surface is positioned in a non-perpendicular alignment with the first surface of the second panel.
 15. The in-situ form as claimed in claim 14, wherein the first panel and the second panel are both made from a material selected from the group consisting of steel, hot-rolled steel, cold-rolled steel, stainless steel, embossed steel, pickled and oiled steel, and steel having a rust inhibitor coating.
 16. The in-situ form as claimed in claim 14, wherein the reinforcement rib defines a shape selected from the group consisting of a C-shape cross-section, a Z-shape cross-section, and a triangular-shape cross-section.
 17. The in-situ form as claimed in claim 16, wherein the C-shape cross-section and the Z-shape cross-section each comprise a base arm, an extension arm connected to the base arm, and a retention arm connected to the extension arm, wherein the retention arm defines the first and second retention surfaces.
 18. The in-situ form as claimed in claim 16, wherein the triangular shape cross-section reinforcement rib comprises three spaced apart rods and an internal support lattice.
 19. The in-place concrete form as claimed in claim 14, wherein the reinforcement rib is made from a material selected from the group consisting of steel, hot-rolled steel, cold-rolled steel, stainless steel, embossed steel, pickled and oiled steel, and coated steel.
 20. The in-situ concrete form as claimed in claim 14, further comprising a removable spacer bar removably positioned between the second surface of the first panel and the second surface of the second panel. 